Method of weaving pile fabrics



Jan. 3, 1956 GRQAT METHOD OF WEAVING FILE FABRICS Filed March 29. .1951

.INVENTOR. fil'wnc zs .P; Groal HTTOENEY.

United States Patent METHOD OF WEAVING PILE FABRICS Francis P. Groat, Bloomsburg, Pa., assignor to The Magee Carpet Company, Bloomsburg, Pa., a corporation of Pennsylvania Application March 29, 1951, Serial No. 218,222

4 Claims. (Cl. 139-39) This invention relates to pile fabrics and method of weaving the same. More particularly, it relates to floor coverings such as carpets and rugs having a cut pile surface wherein the tufts forming the pile have one leg of greater length than the other leg to provide a relatively deep pile.

Heretofore, various methods have been proposed for making pile fabrics having tufts with one leg longer than the other, such as disclosed in the patents to Hope 1,319,- 709 and 1,319,710 and in applicants prior application Serial No. 752,217, now abandoned. In the prior patents and application the methods disclosed employ a combination of knife and hook wires or knife and spoon wires to produce tufts with legs of unequal length. It is an object of the present invention to make a fabric having tufts with legs of unequal length by a method using a pile wire of special shape, similar to the pile wire disclosed in my prior application Serial No. 185,089, now Patent No. 2,674,269.

A further object of the invention is to provide a woven pile fabric having tufts with legs of unequal length projecting from the backing, the tufts in each warpwise now being spaced apart by two weft shots, with the tufts in each weftwise and warpwise row being arranged in staggered relation to the tufts of the next adjacent row.

A further object of the invention resides in a method of weaving a cut pile fabric on a wire loom wherein portions of the pile warps are raised over wires having a straight loop forming portion with a raised portion and knife at one end to form weftwise rows of uncut loops and then successively withdrawing the pile wires to first raise and then cut the loops in each row, the raising of the loops acting to draw the pile warps to reduce the height of one leg of the immediate preceding cut loops in the same pile warps forming tufts with legs of unequal height.

In the accompanying drawing forming a part of this specification and in which like numerals represent like parts throughout the same,

Fig. l is a warpwise section of one dent of the pile fabric,

Fig. 2 is a warpwise section of another dent of the pile fabric,

Fig. 3 is a top plan view of the fabric with the warp and weft threads separated to more clearly show the weave, and

Fig. 4 is a perspective view of the pile wire used in carrying out the method of weaving.

Referring to the drawing, the backing of the fabric is composed of a series of upper and lower weft threads 5 and 6 held together by crossed chain binding threads 7 and 8. Extending longitudinally between the upper and lower series of weft threads are stuiier warps 9 and above the stutter warps directly below the upper weft threads are pile warps 10. In the weave shown in the drawing there is one pile warp in each dent. As clearly shown in Fig. 1, portions of the pile warps are raised between every other pair of upper weft threads and then cut to 2,729,246 Patented Jan. 3, 1956 ice form tufts having a long leg 11 and a short leg 12. While each dent of pile warp has portions raised between every other pair of weft threads, the raised portions in dent two, Fig. 2, are raised between those weft threads that have no raised portions therebetween in dent one, Fig. 1, so that the tufts in dent two are arranged in staggered relation to the tufts in dent one and the tufts of each succeeding dent are staggered with respect to the tufts i1? the immediate preceding dent, as clearly shown in The method of weaving the fabric is carried out on a conventional wire loom employing a series of pile wires 13 of the shape shown in Fig. 4. The wires comprise a shank 14 of uniform height having a loop forming edge 15. At the rear end of the shank is a raised portion 16 connected to the shank by an inclined portion 17 and at the opposite end of the raised portion 16 is a knife edge 18 which rises upwardly from the raised portion. A series of the wires 13 are inserted during the weaving of the fabric. A Wire is inserted between each pair of upper weft shots and the pile warps of every other dent are raised over every other wire while the pile warps of intervening dents are raised over the remaining wires. With the wires inserted the loops in each row will be disposed in staggered relation to the loops of the immediate adjacent row and in the warpwise row of loops therewill be two upper weft shots between hte loops. After inserting the desired number of wires 13 they are successively withdrawn and as each wire is withdrawn the loops formed thereon will be first raised by the inclined portion 17 to the height of the raised portion 16 and then severed by the knife edge 18 forming a row of cut loops or tufts. As the loops are raised by the inclined portion 17 of the wire the pile warps are pulled in a warpwise direction from the preceding row of cut loops thereby lowering the height of one leg of the cut loops in the preceding row so that all the tufts in each weftwise row have one long leg 11 and one short leg 12. As there are two weft shots between the tufts in each warpwise row the short and long legs of the tufts will be securely bound in the backing and will not pull out under ordinary use. I have found a satisfactory carpet can be made by using a wire having a shank inch high over which the loops are formed and a raised portion inch high so that when the loops are raised to the height of the raised portion the leg of the preceding tuft in the same pile warp is reduced inch in height thus forming a tuft having one leg inch high and the other leg inch high. By the method disclosed I have produced a carpet having a high pile surface which requires only the same amount of pile yarn normally required to produce a low pile surface.

Having thus described my invention, I claim:

1. The method of weaving on a wire loom a pile fabric floor covering having a relatively high cut pile face comprising tufts with legs of unequal length which comprises inserting a series of pile wires, each wire having a shank of uniform height with a loop raising portion and cutter at one end, selectively weaving the pile warps over the shanks of alternate wires to form weftwise rows of loops of a height corresponding to the height of the shank, the loops on each wire being disposed in staggered relation to the loops on the next adjacent wire, inserting weft threads above and below the pile warps between each row of loops and successively withdrawing said wires to raise the loops to the height of the raised portion and cut the loops to form rows of relatively high tufts, said pile warps being drawn by the raising of said loops to reduce the height of one leg of the tufts in the preceding alternate row.

2. The method of weaving on a wire loom a pile fabric floor covering having a relatively high cut pile surface zgaagap.

comprising tufts with legs of unequallength which com prises "inserting a se ries of pile wires, each wire having a loop forming shank of uniform height with a loop raising portion at one end of greater height thanthe shank and a cutter on the loop raising'portion, selectiyely weaving the pile warps over the shanks of alterna wires to form we ftwis e rows of loops with the loops on each wire disposed in staggered relation to the loopsonthe next,

adjacent wire, i nsertingweft threads above and below the pile warps between each row of loops, withdrawing a wire to raisethe loops formed thereon to a height corresponding to the heig ht of the loop raising portion andcutting said raised loops to form tufts, and then withdrawingthe next alternate v wire to raise the loops formed thereon whereby the warps of theraised loops are pulled to reduce the heigh t of oneleg of the tufts formed by withdrawal of the first wire.

3. The method of Weaving on a wire loom a pile fabric floor covering having a cut pile face comprising tufts with legs of unequal length which comprises inserting a series of pile wires having a' shank of uniform height with a loop raising portion at one end and a knife edge beyond the loop raisingportion successively insheds of pile warps. selectively weaving portions of the pile warps over the shank of said wires to form weftwiserows of loops with the loops in each row disposed in staggered relation to the. loops in the next adjacent row, inserting Weft threads above and below the pile warps between each row of loops, the loops in each warpwise row being spaced apart b twqnqtt threads 2 5 sassseirsly ,w thdrawiass ist,

wires to raise and cut the loops thereon to form rows of tufts whereby the raising of the loops draws the pile warps to reduce the height of one leg of the tufts in the preceding row formed from the same pile warps.

4. The method of Weavingon a wire loom a cut pile fabric floor covering having a backing with pile warps held therein by elements of the backing, raising the pile warps selectively from the backing and restoring said pile warps" to the backing to form transverse rows of portions of the pile' warps projecting above thcbacking to form pile loops, the loops in each row being arranged in staggered relation to theloops in the-next adjacent rows, successively r aising and cutting each row of loops to form tufts whereby the pile warps are pulled to reduce the height of a leg of the tufts in the preceding row formed from the same pile warps.

References Cited in thefile of this patent. 

